Large Loss Lessons Learned
Corrosive Chemical Causes Injury
An environmental contractor had a project to remove
a highly concentrated sodium hydroxide mixture from
a 2,000-gallon storage tank at a customer's site.
The technician was using a vacuum truck to remove
the product through a one-inch hose line running from
the storage tank to the truck. There was a safety
shower located within close proximity, and the technician
was wearing a disposable chemical protective suit,
a face shield, respirator, chemical-resistant gloves,
and safety shoes. The chemical suit was rated to withstand
several hours of direct exposure to caustic materials.
A leak occurred at the hose connection, and the technician
was splashed with a small amount of caustic down the
front of his unzippered chemical suit. He was instructed
by his supervisor to go to the restroom to "clean
up". He sponged himself off at the sink, put
back on the same clothes, and went out to lunch with
his co-workers. Upon return from lunch he complained
of a burning sensation to his chest and abdomen, and
was taken to a nearby medical clinic for treatment.
He was subsequently treated and sent home, but had
to return later that night to the emergency room for
additional medical treatment.
Consequences
-
The injuries required skin grafts,
physical therapy, and several months of lost work
time.
-
The total cost of the accident including
medical bills, rehabilitation, and compensation
was over $100,000.
-
Additional untracked costs included
the employee's pain and suffering, the company's
lost productivity, and the negative affect on employee
morale following the accident.
Primary Causes
There were several underlying causes that
contributed to the accident including:
-
The chemical suit provided to the
employee was too small and tight-fitting, making
it uncomfortable for him to move about.
-
The employee kept the front panel
of his chemical suit unzippered to allow for easier
movement. By having the suit open the caustic was
able to get inside the suit rendering its chemical-resistant
qualities virtually ineffective.
-
The affected skin should have been
thoroughly rinsed in the safety shower and subsequently
washed in the locker room shower.
-
The contaminated clothing should
not have been put back on until they had been properly
cleaned.
-
A delay in providing adequate medical
evaluation and treatment allowed the chemical burns
to progress causing additional skin damage.
-
As part of a personal protective
equipment (PPE) hazard assessment a variety of types
and sizes of PPE should be made available. A PPE
Hazard Assessment consists of an organized method
of categorizing risk exposure in terms of potential
to cause injury, as well as what parts of the body
need to be protected. In the example above, determining
the requirement for wearing a chemical resistant
suit was based on the corrosive nature of the chemicals
being handled. Similarly, the need for face shields,
chemical resistant gloves, and safety shoes were
determined through the Hazard Assessment of the
project.
-
Upon initial exposure to the caustic,
the technician should have been instructed to immediately
remove his suit, and rinse off thoroughly under
the safety shower.
-
He should have been sent immediately
to the health clinic as a precautionary measure,
rather than waiting until later that afternoon when
the caustic had additional time to cause serious
skin burns.
-
Hazard communication training that
is chemical specific is important so that employees
know the signs and symptoms of exposure and the
appropriate first aid measures to take following
a concentrated caustic chemical exposure.
-
The contaminated clothing should
have been discarded or properly laundered.
Actions Taken
The environmental contractor adopted the use of a
PPE Hazard Assessment to determine the personal protective
measures required to perform specific jobs safely.
A sample Hazard Assessment form is available through
the Risk Control division of XL Insurance.
Following the accident, safety training meetings
were held to stress the importance of selecting, inspecting,
and using personal protective equipment based on the
chemical specific hazards anticipated.
Employees and supervisors were provided with a review
of emergency procedures to follow in the event of
a hazardous material accident/incident.
Chemical suits and other PPE of all sizes were ordered
to ensure that employees were properly outfitted.
Please contact an XL Insurance risk control consultant
at +1 800-327-1414 if you have any questions regarding
PPE Hazard Assessments, or other health, safety, or
environmental issues affecting your operations.
"XL Insurance" is a registered trademark
of XL Capital Ltd. XL Insurance is the global brand
used by member insurers of the XL Capital Ltd group
of companies.
For general information purposes only. Contents
should not be construed or used as legal advice or opinion.
XL Insurance
520 Eagleview Blvd
PO Box 636
Exton, PA 19341-0636
Tel: +1 800-327-1414
Fax: +1 610-458-8667
www.xlinsurance.com/environmental
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